U.S. patent application number 16/537901 was filed with the patent office on 2020-04-09 for remote facade inspection gantry.
The applicant listed for this patent is RevolutioNice Inc.. Invention is credited to Elie Cherbaka, Ryan J. Giovacchini, Brian Jennings, Sreenivas Raman, Thomas C. Slater.
Application Number | 20200109972 16/537901 |
Document ID | / |
Family ID | 67543467 |
Filed Date | 2020-04-09 |
United States Patent
Application |
20200109972 |
Kind Code |
A1 |
Raman; Sreenivas ; et
al. |
April 9, 2020 |
REMOTE FACADE INSPECTION GANTRY
Abstract
A facade gantry allows for close inspection of a facade using
remotely operated cameras, probes, and/or sampling devices. These
devices are located in a housing that is positioned in front of a
facade by a system of cables, from which it is suspended, that
allow for movement in any direction in a plane. Two cables are
attached to the housing containing the sensors and tools and are
wound onto two separate spools located on the roof at the vertical
boundaries of the inspection area. By winding and unwinding these
spools, the housing can be raised, lowered, and moved from side to
side. The invention further has an optional "shed" located on the
ground that protects pedestrians in the case of a suspension system
failure. The shed moves to maintain a position directly under the
housing. The gantry optionally allows for repair of the facade by
using remotely operated repair tools.
Inventors: |
Raman; Sreenivas; (Park
Ridge, NJ) ; Cherbaka; Elie; (Franklin Lakes, NJ)
; Giovacchini; Ryan J.; (Trenton, NJ) ; Jennings;
Brian; (Merrmack, NH) ; Slater; Thomas C.;
(New York, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
RevolutioNice Inc. |
Belleville |
NJ |
US |
|
|
Family ID: |
67543467 |
Appl. No.: |
16/537901 |
Filed: |
August 12, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15206167 |
Jul 8, 2016 |
10378935 |
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16537901 |
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62190214 |
Jul 8, 2015 |
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62193565 |
Jul 16, 2015 |
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62276218 |
Jan 7, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04G 23/0296 20130101;
G01D 11/24 20130101; G01D 11/30 20130101; E04G 3/30 20130101; E04G
23/00 20130101; E04G 3/34 20130101 |
International
Class: |
G01D 11/30 20060101
G01D011/30; E04G 23/02 20060101 E04G023/02; E04G 23/00 20060101
E04G023/00; G01D 11/24 20060101 G01D011/24 |
Claims
1. A facade inspection and repair system comprising: a housing; an
inspection tool operationally connected to the housing; a plurality
of cables from which to suspend the housing; and a controller
operationally connected to the cables; a first outrigger brace
configured to cantilever out from an upper portion of a building,
wherein the first outrigger brace comprises a first motorized cable
spool and a first pulley disposed adjacent an end of the first
outrigger brace; and a second outrigger brace configured to
cantilever out from the upper portion of the building, the second
outrigger brace being spaced apart from the first outrigger brace
along the upper portion of the building, wherein the second
outrigger brace comprises a second motorized cable spool and a
second pulley disposed adjacent an end of the second outrigger
brace, wherein: the plurality of cables comprise: a first cable
that is at least partially wound around the first motorized cable
spool and extends from the first motorized cable spool through the
first pulley to the housing; a second cable that is at least
partially wound around the second motorized cable spool and extends
from the second first motorized cable spool through the second
pulley to the housing; the controller is configured to: cause the
first motorized cable spool to release and retract the first cable;
and cause the second motorized cable spool to release and retract
the second cable; and the first motorized cable spool and the
second motorized cable spool are configured to cooperate to adjust
a position of the housing in a plane that is parallel to the facade
of the building and offset from the facade of the building by a
distance defined by a distance between the facade of the building
and the first and second pulleys.
2. The facade inspection system of claim 1, further comprising a
third motorized cable spool disposed in a fixed position adjacent a
ground in front of the building; and a third cable that is at least
partially wound around the third motorized cable spool and extends
from the third motorized cable spool to the housing.
3. The facade inspection system of claim 2, further comprising a
fourth motorized cable spool disposed in a second fixed position
adjacent the ground in front of the building; and a fourth cable
that is at least partially wound around the fourth motorized cable
spool and extends from the fourth motorized cable spool to the
housing.
4. The facade inspection system of claim 1, wherein the housing
comprises one or more propellers configured to adjust a position of
the housing relative to the facade of the building.
5. The facade inspection system of claim 1, further comprising at
least one tool disposed adjacent the housing.
6. The facade inspection system of claim 5, wherein the at least
one tool is configured to apply grout on the facade.
7. The facade inspection system of claim 5, wherein the at least
one tool is configured apply material to the facade.
8. The facade inspection system of claim 7, wherein the at least
one tool is configured to apply the material between two elements
of the facade.
9. The facade inspection system of claim 8, wherein each of the two
elements comprise a brick.
10. A facade inspection system comprising: a housing; an inspection
tool operationally connected to the housing; a repair tool disposed
on the housing; a plurality of cables from which to suspend the
housing; and a controller operationally connected to the cables,
wherein: the facade inspection system further comprises: a first
outrigger brace configured to cantilever out from an upper portion
of a building, wherein the first outrigger brace comprises a first
motorized cable spool and a first pulley disposed adjacent an end
of the first outrigger brace; and a second outrigger brace
configured to cantilever out from the upper portion of the
building, the second outrigger brace being spaced apart from the
first outrigger brace along the upper portion of the building,
wherein the second outrigger brace comprises a second motorized
cable spool and a second pulley disposed adjacent an end of the
second outrigger brace; and the plurality of cables comprise: a
first cable that is at least partially wound around the first
motorized cable spool and extends from the first motorized cable
spool through the first pulley to the housing; a second cable that
is at least partially wound around the second motorized cable spool
and extends from second first motorized cable spool through the
second pulley to the housing; the controller is configured to:
cause the first motorized cable spool to release and retract the
first cable; and cause the second motorized cable spool to release
and retract the second cable; the first motorized cable spool and
the second motorized cable spool are configured to cooperate to
adjust a position of the housing in a plane that is parallel to the
facade of the building and offset from the facade of the building
by a distance defined by a distance between the facade of the
building and the first and second pulleys.
11. The facade inspection system of claim 10, wherein: the facade
inspection system further comprises a safety shed disposed adjacent
a ground in front of a facade of the building and comprising: a
rectangular frame; a roof disposed adjacent an upper portion of the
rectangular frame; a third motorized cable spool disposed on the
roof; and at least one wheel; and the plurality of cables further
comprise a third cable that is at least partially wound around the
third motorized cable spool and extends from the third motorized
cable spool to the housing.
12. The facade inspection system of claim 11, wherein the first
cable, the second cable, and the third cable are configured
cooperate to maintain the housing a fixed distance from the
facade.
13. The facade inspection system of claim 11, wherein the third
cable is configured to remain in tension between the housing and
the third motorized cable spool.
14. The facade inspection system of claim 11, wherein the shed is
configured to roll on the at least one wheel along the ground in
front of the facade of the building.
15. The facade inspection system of claim 14, wherein the
controller is configured to cause the shed to maintain a position
that is directly beneath the housing such that the shed is disposed
between the housing and the ground as the housing moves within the
plane.
16. The facade inspection system of claim 10, wherein the housing
comprises one or more propellers.
17. The facade inspection system of claim 16, wherein the one or
more propellers are configured to adjust a relative position of the
housing relative to the facade of the building.
18. The facade inspection system of claim 17, wherein the housing
comprises a quadcopter.
19. The facade inspection system of claim 18, wherein the first
motorized cable spool and the second motorized cable spool are
configured to slacken the first cable and the second cable to allow
for free movement of the housing through operation of the
quadcopter.
20. A facade inspection and repair system comprising: a housing; a
repair tool operationally connected to the housing; a plurality of
cables from which to suspend the housing; and a controller
operationally connected to the cables; a first outrigger brace
configured to cantilever out from an upper portion of a building,
wherein the first outrigger brace comprises a first motorized cable
spool and a first pulley disposed adjacent an end of the first
outrigger brace; a second outrigger brace configured to cantilever
out from the upper portion of the building, the second outrigger
brace being spaced apart from the first outrigger brace along the
upper portion of the building, wherein the second outrigger brace
comprises a second motorized cable spool and a second pulley
disposed adjacent an end of the second outrigger brace; and a third
motorized cable spool disposed in a fixed position adjacent a
ground in front of the building, wherein: the plurality of cables
comprise: a first cable that is at least partially wound around the
first motorized cable spool and extends from the first motorized
cable spool through the first pulley to the housing; a second cable
that is at least partially wound around the second motorized cable
spool and extends from the second first motorized cable spool
through the second pulley to the housing; and a third cable that is
at least partially wound around the third motorized cable spool and
extends from the third motorized cable spool to the housing; the
controller is configured to: cause the first motorized cable spool
to release and retract the first cable; and cause the second
motorized cable spool to release and retract the second cable; and
the first motorized cable spool and the second motorized cable
spool are configured to cooperate to adjust a position of the
housing in a plane that is parallel to the facade of the building
and offset from the facade of the building by a distance defined by
a distance between the facade of the building and the first and
second pulleys.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS.
[0001] This application is a continuation of application Ser. No.
15/206,167, filed Jul. 8, 2016 (now, U.S. Pat. No. 10,378,935),
which claimed the benefit of the following U.S. Provisional
Applications: (1) Ser. No.: 62/190,214, filed Jul. 8, 2015; (2)
Ser. No.: 62/193,565, filed Jul. 16, 2015; and (3) Ser. No.:
62/276,218, filed Jan. 7, 2016, the contents of each of which are
incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] Embodiments of the present invention include building
inspection systems, and more specifically, facade inspection
systems.
BACKGROUND OF THE INVENTION
[0003] Building facades are large, difficult to access and require
regular inspection to ensure that they are in good condition and
have not degraded in a manner that exposes building occupants or
passersby to danger. Currently, facade inspectors rely on aerial
work platforms or scaffolding to position themselves close enough
to the facade to adequately inspect it. The use of lifts and
scaffolding is expensive, time consuming, and exposes the inspector
to a fall risk. A system to allow for remote detailed inspection of
facades would minimize these problems, reducing the cost and time
needed for facade inspections as well as eliminating the risk to
workers and inspectors of injury as they would otherwise need to
work at great heights.
BRIEF SUMMARY OF THE INVENTION.
[0004] An object of the present invention is a facade inspection
system.
[0005] Another object of the present invention is a remote
controlled facade inspection system.
[0006] And another object of the present invention is a partially
automated facade inspection system.
[0007] Yet another object of the present invention is a facade
repair system.
[0008] Still another object of the present invention is a remote
controlled facade repair system.
[0009] And another object of the present invention is a partially
automated facade repair system.
[0010] An embodiment of this invention allows for close inspection
of a facade using remotely operated cameras, probes, and/or
sampling devices. These devices are located in a housing that is
positioned in front of a facade by a system of cables, from which
it is suspended, that allow for movement in any direction in a
plane. Two cables are attached to the housing containing the
sensors and tools and are wound onto two separate spools located on
the roof at the vertical boundaries of the inspection area. By
winding and unwinding these spools, the housing can be raised,
lowered, and moved from side to side. In various other embodiments
of the invention, one or more cables extend from the housing to a
device located on the ground. In one embodiment, cable will extend
down from the housing to a powered "shed" located on the ground
that protects pedestrians in the case of a suspension system
failure. The shed moves to maintain a position directly under the
housing. The cable attaching the housing to the shed is tensioned
to reduce the possibility of the housing swinging towards or away
from the facade. As the operator signals for the housing to move,
the cables are either wound onto or unwound from the powered spools
to achieve the desired housing movement and the shed moves to
remain beneath the housing.
[0011] In other embodiments, one or two powered spools are located
in fixed positions on the ground and are used to aid in positioning
the housing and reduce any wind-induced swaying. One or more of the
cables may optionally also contain, carry, or function as a data
and power link that allows for the real time transmission of sensor
data and the operation of equipment located in the housing or data
transmission between the housing and controller may be wireless and
housing power may be supplied by an onboard battery.
[0012] In various embodiments, tools mounted in the housing are
able retrieve facade material for later analysis or use tools and
sensors to probe, analyze, and/or repair the facade.
[0013] In some embodiments, the housing has the functionality of or
is rigidly attached to a quadcopter. In this embodiment, the
housing can fly to the facade from an initial suspended position,
affix itself to the facade and perform needed operations. All
components are controlled by an operator using a controller that
also allows real time monitoring of the system. The data generated
by the device can be used to create highly detailed images and
three dimensional models of the facade which can then be analyzed
to determine if there are any problems with the facade that require
repair.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING.
[0014] FIGS. 1-13 show various embodiments and details of the
invention.
DESCRIPTION OF THE INVENTION.
[0015] The cable positioning system comprises two powered spools
that are mounted on the roof of the building. As the housing will
not be able to move the location of the spools, they establish the
vertical boundaries of the inspection area. A cable from each spool
is attached to the housing as are any necessary data and power
connections. The cables are routed through fixtures, preferably
outrigger braces, that cantilever out from the face of the building
and beyond any building features that may interfere with the
movement of the housing, such as fire escapes and balconies. By
winding and unwinding cable from the pulleys, the position of the
housing in a plane that is parallel to the building facade and
offset from it a distance determined by the length of the
cantilevered fixtures can be changed.
[0016] In some embodiments, there is a distinct data cable. The
data cable may be integrated with the suspension cables or may be a
separate cable with a dedicated powered spool that is computer
controlled to ensure an adequate but not excessive length of cable
has been paid out.
[0017] Control software is able to dynamically change the rate at
which each spool either releases or retracts cable to move the
housing in a manner that is consistent with the desired movement as
input to a controller by an operator. For example, for the housing
to move in the horizontal direction while suspended below the two
spools, they will have to constantly adjust the rate at which cable
is being released and retracted, while the operator will only have
to indicate that a horizontal movement is desired.
[0018] The housing encloses and provides a mounting area for tools
and sensors and protects them from adverse weather and possible
collisions with the building facade. The number and kind of sensors
and tools inside the housing may be varied depending on the
requirements of the job. Additionally, it is easy to add and
replace components to increase the functionality or reduce the cost
of the device. In most cases, there is a video and/or still camera
that allows for the remote operator to visually inspect aspects of
the facade and save image data for later analysis and/or the
creation of three dimensional models. In various embodiments of the
invention, the cameras are mounted on a gimbal to allow for their
orientation to be changed if desired by an operator and/or are able
to zoom in and out. Cameras that use wavelengths that are not
visible by humans, such as infrared, are also present in various
embodiments of the invention.
[0019] Other sensors and tools may need to be positioned very close
to the facade and move independently of the housing to perform
their intended function. To achieve this, in some embodiments of
the invention, a device or manipulator to position a tool is
integrated with the housing. The device, possibly a small multiaxis
robotic arm, is capable of precise movements in very close
proximity to the facade. It can also be used to with tools and
sensors manipulate and probe the facade surface. For example, it
may position and drive a drill into the facade in order to collect
material for later analysis or to allow observation of the behavior
of the subject material to determine its properties. Other possible
sensors requiring close proximity to the facade and a precise
positioning system include moisture sensors and borescopes.
[0020] In other embodiments of the invention, the housing has
integrated propellers, motors, and controls to allow for flight
capabilities along the lines of existing quadcopters or the housing
may be affixed to a quadcopter. In this embodiment of the
invention, the housing is positioned as described above unless the
operator desires to be positioned closer to the facade to allow for
more detailed inspection or the manipulation of facade elements.
The device can enter a flight mode during which the device is
positioned solely by the use of the propellers. While in this mode,
the cables of the suspension system are slackened to allow for the
free movement of the housing, but would prevent the device from
falling to the ground in the event of a flight systems failure.
[0021] In some embodiments, the housing incorporates devices,
possibly employing electrostatic adhesion, that allow it to be
temporarily affixed to the facade and act as a stable platform for
observing, measuring, probing, manipulating, altering, or affecting
the facade. The system for temporarily affixing the device to the
facade incorporates structural members that separate the housing
from the adhesion components to create a gap between the housing
face and the facade where tools and components can maneuver to
achieve desired positions and configurations.
[0022] In some embodiments, the invention is capable of performing
repairs to mitigate potential hazards. If a loose brick is
observed, the device is able to affix netting to the facade to
cover the brick to minimize danger until a more substantial repair
can be performed. The invention has the capability of using
different tools to affect different repairs. The manipulator is
able to change tools using a tool changing mechanism that is
affixed to the housing or, in another embodiment, the operator will
retrieve the housing and manually attach a new tool to the
manipulator. Possible end-of-manipulator tools include applicators
capable of applying grout or tape. At the direction of the
operator, either material can be applied to the facade or between
facade elements in order to stabilize a section of facade that may
be in danger of falling.
[0023] As there is a risk of debris falling from the facade during
both inspection and repair work, in some embodiments of the
invention, a system to catch small pieces of falling debris is
present. The system consists of a net that can be quickly deployed
and can span the distance between the housing and the facade. When
not needed, it is retracted and stored in a manner that reduces the
likelihood of it interfering with or catching on any part of the
facade while the device is operating. When stored it also minimizes
the force exerted by wind on the device.
[0024] When hoisting or suspending heavy materials from buildings
in busy urban areas, the possibility of an unintended release of
material needs to be accounted for. A temporary roof structure
called a sidewalk shed is often constructed to shelter pedestrians
from falling objects. These sheds are large and take time and money
to erect. In various embodiments of this invention, there is a
small, powered shed able to travel the length of the facade along
the sidewalk to maintain a position directly beneath the housing.
In various embodiments, a third powered cable spool will be mounted
on this shed and a cable will extend from it up to the housing.
This third cable will allow for the distance between the housing
and the facade to be fixed as it eliminates a degree of freedom or
movement which increases stability of the housing and its
associated sensors and tools. This third cable may also contain,
carry or function as a power and data link to allow for the
transmission of housing location information to the shed and data
and power as needed.
[0025] In various embodiments of the invention, the shed is not
present and one or more powered spools are located on the ground
with cables that are connected to the housing. These will act to
reduce the possibility of housing movement towards or away from the
facade and aid when the housing is directed to be positioned
towards the boundaries of the plane in which it can move.
[0026] The devise is operated using a controller that allows for a
human to direct the housing motion and the operation of sensors and
tools. The controller also presents real time video and sensor data
to the operator and allows for data to be saved for later analysis.
The operator has the ability to note and save the position of the
device at any point to allow for easy re-inspection of facade
areas. The controller is capable of automatically guiding the
device to a saved position from any point. Saved locations are able
to be indexed and browsed with a photo of the facade area that is
most easily observed from the corresponding position representing a
device position. Data is from the housing to the controller through
a wired connection to the housing or, in some embodiments,
wirelessly.
[0027] In use, the invention is employed as described above.
[0028] Although this invention has been described with a certain
degree of particularity, it is to be understood that the present
disclosure has been made only by way of illustration and that
numerous changes in the details of construction and arrangement of
parts may be resorted to without departing from the spirit and
scope of the invention.
* * * * *